Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02574752 2007-01-22
HIGH MAST INSPECTION SYSTEM, EQUIPMENT AND METHOD
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims benefit of priority from U.S. Provisional
Applications Serial Nos. 60/760,683 and 60/772,212, filed January 20, 2006 and
February 10, 2006, respectively, and both entitled "High Mast Inspection
System
and Method." The entire disclosures of each of the aforementioned patent
applications are expressly incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention generally relates to inspection of high mast
structures typified by high mast lighting towers and more particularly to a
unique
inspection system and method.
High mast towers are tall, reaching heights of several hundred feet, thus
creating a problem of manually inspecting the upper portions of the tower for
structural integrity including, inter alia, weld cracks, corrosion,
straightness, loss
of protective surface finish, dents, punctures, and other structural damage or
weakness. Practitioners required to inspect a tower are either required to
view
the tower from a ground location using unaided eyesight, binoculars or a
telescope, a method that does not allow a significantly close inspection of
the
tower for flaws, or they are required to be raised in a bucket to a higher
level to
perform a similar analysis, which can be very dangerous and such buckets
rarely
can reach the upper regions of the high mast towers. These methods of
inspection more often are expensive, dangerous, and ineffective.
Other reported experimental methods of inspection involve robotic devices
capable of independently climbing a high mast tower. Such inspection methods,
while providing closer and more level views of the structure, are problematic
in
several respects. Existing inspection robots only enable inspection of one
view
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of the tower. Thus, several trips up and down the structure usually are
necessary for a full inspection.
Magnetic elements enable these robots to move up and down the
structure. Thus, a problem arises when the high mast structure is constructed
out of a non-magnetic material and the robot is not capable of climbing the
tower.
Magnetic adhesion to the tower also limits the weight capacity of the robots,
as
they often cannot carry all of the desired equipment up the tower. Such
robots,
beyond containing an already expensive inspection system, also must provide
motion and climbing capabilities; thus, adding a great deal of further expense
to
the system.
A need arises to provide for inspection of high mast towers and other very
tall structures that is effective and provides for a level of inspection of a
substantial portion of even the tallest high mast towers and other structures,
while at the same time avoid being time intensive, prohibitively expensive, or
inherently dangerous to practitioners utilizing it. Since most high mast
maintenance people are not well trained in crack analysis and operation of
highly
sophisticated electronic equipment, a desired system would be very simple to
use and require little extended education for the operator. It is to such a
system
that the present invention is addressed.
BRIEF SUMMARY OF THE INVENTION
For purposes of this application, upright structures typified by high masts
or poles, such as support light rings, are inspected for an adverse surface
condition, such as a flaw, defect, crack, corrosion, erosion, abnormality,
irregularity, or other deviation that compromises the integrity and/or
functionality
of the pole, eventually requiring repair and/or replacement. Such surface
conditions often will be referred to as an "anomaly" herein for convenience
and
not by way of limitation. By "mast" is meant a generally vertical or upright
structure, which in the vernacular often is referred to as a pole, tube, rod,
shaft,
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flagstaff, post, wand, tower, or similar upstanding structure. Mast, then, is
to be
interpreted broadly in accordance with the intent of the disclosure set forth
herein.
An inspection system for removably mounting to a platform movable in
relation to a generally upright mast for inspection of the mast has a mounting
support assembly removably fixable to the plafform. A detector device is
carried
by the mounting support assembly for scanning the mast and collecting mast
scanned information. A power supply is carried by one or more of the mounting
support assembly or the detector device and is connected to the detector
device.
A communications device is carried by one or more of the mounting support
assembly or the detector device and is connected to the detector device for
receiving and relaying the collected mast scanned information.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and advantages of the present
invention, reference should be had to the following detailed description taken
in
connection with the accompanying drawings, in which:
Fig. 1 is a schematic perspective view of an exemplary embodiment of an
aspect of the inspection system;
Fig. 2 is a perspective view of an exemplary embodiment of the mounting
support assembly;
Fig. 3 is a perspective view of an exemplary embodiment of the mounting
support assembly;
Fig. 4 is a perspective view of an exemplary embodiment of a joint of the
mounting support assembly;
Fig. 5 is an operative view of an exemplary embodiment of the mounting
support assembly in relation to the platform near the base of the structure
for the
inspection system;
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Fig. 6 is an operative view of an exemplary embodiment of the mounting
support assembly in relation to the platform near the apex of the structure
for the
inspection system;
Fig. 7 is a schematic block diagram of an exemplary embodiment of the
communication aspect of the inspection system;
Fig. 8 is an operative view of an exemplary embodiment of the graphical
user interface/computer interface of the inspection system;
Fig. 9 is a schematic plan view of an exemplary embodiment of an aspect
of the inspection system;
Fig. 10(A) is an operative view of an exemplary embodiment of the
graphical user interface/computer interface of the inspection system;
Fig. 10(B) is an enlarged partial view of the interface shown in Fig. 10(A);
Fig. 11 is a plan view of a commercial camera pod assembly (detector
device) affixed to a luminaire ring;
Fig. 12 is an image of a commercial viewer/transceiver screen showing
screens where images of a mast crack and different sides of a mast are
displayed;
Fig. 13 is an image of the commercial viewer/recorder screen;
Fig. 14 is a schematic block diagram of a commercial embodiment of the
communication aspect of the inspection system; and
Fig. 15 is a functional flow diagram of a commercial version of the
disclosed inspection system.
The drawings will be described in further detail below.
DETAILED DESCRIPTION OF THE INVENTION
The inventive inspection system can be used to check one or more of the
following exemplary mast defects: weld cracks, spot loss of galvanization,
dents,
tears, corrosion (rust), buried foundations, missing/loose nuts, missing/loose
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access covers, graffiti, and the like. Such inspection system also provides
storable and retrievable data files depicting the condition of the mast
(including
surface condition). The novel inspection system interfaces with a database
that
includes mast identification (including GPS location). The database created
can
be used, inter alia, to establish a baseline of a "healthy" mast following
initial
installation. The database also can be used to create a report establishing
the
changes/differences between the current inspection and all prior inspections.
Moreover, the inventive inspection system is portable and quite usable by
current
maintenance mast inspection personnel. The novel inspection system, then, is
cost effective.
Fig. 1 provides a schematic perspective view of an embodiment of an
inspection system, 1000, that can be used for inspecting, viewing and/or
scanning, a structure, 1010, such a mast pole or the like. A mounting support
assembly, 1100, can at least partially enclose, encircle and/or surround
structure
1010. Moreover, mounting support assembly 1100 may be located at least
partially inside of or on an interior position of a structure, as
schematically
illustrated in Fig. 9. Further, mounting support assembly 1100 may be located
at
any variety of locations with respect to the structure, such as, but not
limited
thereto, above or below. Structure 1010 can be a high mast lighting tower
(e.g.,
roadway, shipping ports, parking lot, and athletic stadiums/facilities), cell
tower,
and/or an antenna tower, cranes, various vertical piping, vertical tubing,
vertical
girders, vertical bits, elevator shaft infrastructure, vertical off-shore
platform
structure, theme park or ball park vertical structure, or any other desired
vertical
structures or towers. Such vertical structures are generally vertically
aligned
which includes an angle or alignment. Additionally, the structure may be for
example, elevator cables or electrical cables that require inspection.
Moreover, it
should be appreciated that the structure may be any erected structure
requiring
inspection, survey or communication therewith. The structure or equipment for
inspection may be any vertically-oriented above-surface or vertically-oriented
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sub-surface structure or equipment. In an embodiment, mounting support
assembly 1100 may be any variety of type of bands or rings. Moreover,
mounting support assembly 1100 may have any variety of shapes, sizes,
dimensions, or attributes so as to accommodate a given platform, 1020, and/or
structure 1010 requiring inspection or monitoring. The band or ring may be a
wide variety of circumferential shapes or semi-circumferential shapes such as,
but not limited to, polygon, hexagon, rectangle, and/or an octagon, etc.
Similarly,
the band may be a circle, oval, bow, curve, and/or an arc, etc. Mounting
support
assembly 1100 may be individual components intermittently (i.e., non-
continuous) mounted on platform 1020, such as a lowering ring. Platform 1020
can be a lighting rack, maintenance rack, robot, cleaning/monitoring device,
an
observation deck, top or bottom of elevator (or other specified location), or
any
structure or equipment that may be found on or with an erected structure or
equipment (above or below a surface).
Components of inspection system 1000 can be at least partially supported
by or disposed on structure 1010, mounting support assembly 1100 and/or
platform 1020, as well as any proximal or remote location from the structure
under inspection or monitoring. Components of inspecting system 1000 can be
removably mounted on platform 1020, structure 1010, or mounting support
assembly 1100, as well as any proximal or remote location from the structure
under inspection or monitoring. Mounting support assembly 1100 can be
coupled to platform 1020 by a variety of attachment devices or means 1030, for
example a tether. Attachment or coupling device 1030 may be a tie rope, cord,
hinge, lock, pivot, coupling, key, latch, lug, nail, dowel, nut and bolt,
screw, latch,
lock, joint and/or a clamp, etc. It should be appreciated that various
components
of the inspection system or a portion thereof can be permanently or removably
affixed to the platform and/or structure.
Inspecting system 1000 further comprises a detector device 1200.
Detector device 1200 can comprise a video camera, a digital video camera,
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thermal imaging camera, radio frequency detector, a still-life camera,
ultrasonic
device, eddy current device, magnetic particle inspection (MPI), magnetic
resonance imaging (MRI) device, any data acquisition device, etc., including
for
detecting/sensing roll, pitch, yaw, height, direction (compass), and the like.
The
detector device (as well as the auxiliary device or external device) can
itself
comprise a robotic system for additional reach on structure 1010. Detector
device 1200 is adapted to transmit and/or receive data. Such transmission may
be wireless or hard-wired, such as but not limited thereto being implemented
using wire, cable, fiber optics, phone line, cellular phone link, RF link,
Blue Tooth,
infrared link, integrated circuits, and other communications channels.
Detector
device or means 1200 may have pan, tilt, focus, and/or zoom capabilities.
Detector device 1200 may have recording and memory storage capabilities, as
well as data processing capabilities. Detector device 1200 may be mounted on
mounting support assembly 1100 and/or on platform 1020. It should be
appreciated that the detector devices may be used for monitoring, inspecting
and/or positioning. Similarly, other devices or instruments may be substituted
or
added to accomplish the same function(s).
Inspection system 1000 further comprises a transmitter and/or receiver
1300. Transmitter/receiver (or transceiver) 1300 may be operatively coupled to
detector device 1200. It should be appreciated that the transmitter device,
receiver device and detector can be separate or integral units. Moreover,
there
may be a plurality of transmitter and receiver devices utilized in inspection
system 1000 so as to allow any of the modules/devices/instruments/processors
to communicate with one another. Transmitter and/or receiver 1300 can be
operatively coupled to a controller (as shown in Fig. 7). Transmitter and/or
receiver 1300 may comprise a wireless transmitter/receiver and is adapted to
receive and transmit data. Accordingly, transmitter and/or receiver 1300 may
be
adapted to transmit via a physical connection or wireless connection, such as,
but not limited to, cable, wire, optical fiber, phone line, cellular phone
link,
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integrated circuit, RF link, Blue Tooth, infrared link and other
communications
channels, etc. Transmitter and/or receiver 1300 may be removably and/or
permanently affixed to plafform 1020, structure 1010 and/or mounting support
assembly 1100. It should be appreciated there may be a plurality of
transmitters
and/or receivers 1300 in communication with any of the various components or
modules of inspection system 1000 that are mentioned herein. The transmitters
and/or receivers may be integral or separate with one another. Moreover, the
transmitter and/or receivers may be integral or separate with any of the
various
components or modules of inspection system 1000 that are mentioned herein.
Inspecting system 1000 may comprise a power supply 1400 as shown in
Fig. 1. Power supply 1400 can be operatively coupled to detector device 1200
and/or transmitter and/or receiver 1300. It should be appreciated that power
supply 1400 and detector device 1200 (or any other equipment, tool,
instrument,
system mentioned herein) may be separate or integral units. Similarly, it
should
be appreciated that power supply 1400 and transmitter and/or receiver 1300 (or
any other equipment, tool, instrument, system mentioned herein) may be
separate or integral units. Further, it should be appreciated that power
supply
1400, transmitter and/or receiver 1300 and detector device 1200 (or any other
equipment, tool, instrument, system mentioned herein) may be integral units.
Power supply 1400 can be an independent power supply, such as, but not limited
to, a generator, battery and/or solar array, etc. Power supply 1400 may be a
dependent power supply. It should be appreciated that the power supply may be
located on any component of the inspection system or may be proximally located
such as at the base of the structure or remotely from the structure (or area
under
inspection). The transmission of power to the system may be of any available
means.
Further, inspection system 1000 also may comprise or be in
communication with an auxiliary system/device/instrument 1600, as well as a
plurality of such systems/devices/instruments. Such auxiliary
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system/device/instrument 1600 may include, but not limited thereto, the
following:
communication devices/systems, robots, global positioning systems, positioning
devices/systems, monitoring device/system or laser device or any other
device/system/instrument as desired or required.
Fig. 2 is a perspective view of an embodiment of mounting support
assembly 1100. Mounting support assembly 1100 may be of a one-piece and/or
multi-piece design. Mounting support assembly 1110 may comprise a first
segment 1110 and/or a second segment 1120. Second segment 1120 can be
releasably coupled to first segment 1110. First segment 1110 and/or second
segment 1120 may be detachable from mounting support assembly 1100.
Mounting support assembly 1100 may comprise a third segment 1125. It should
be appreciated that mounting support assembly 1100 may comprise more than
three segments. The mounting support assembly may be formed to provide a
complete perimeter around the structure or rather only intermittent or
staggered
portions around, inside or adjacent to the structure or equipment being
inspected
or monitored. The segment members may be, but not limited thereto, the
following: plates, posts, arms, branches, fingers, frames, legs, rods,
sleeves,
struts, tracks, trusses, shoulders, or studs, as well as any combination
thereof.
Fig. 3 is a perspective view of an embodiment of mounting support
2o assembly 1100. Mounting support assembly 1100 may be shaped substantially
in the form of a band or ring having a variety of circumferential shapes or
semi-
circumferential shapes such as, but not limited thereto, polygon, regular
polygon,
rectangular, hexagon, octagon, circular, oval or arc-shaped, etc. Mounting
support assembly 1100 may have an adjustable diameter as referenced as D, for
example. The diameter, D, of the band may be any variety of sizes or dimension
so as to accommodate, the structure or equipment, mounting support assembly,
plafform and/or various components/modules/instruments of the inspection
system. Mounting support assembly 1100 can be constructed of a variety of
materials such as, but not limited to metals, steels, alloys, wood,
composites,
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polymers, plastics, or any combination thereof. The material may be any
suitable
material or composite necessary to accomplish the desired function. The
mounting support assembly may be a variety of rigid structures such as
perforated steel as shown. By way of example only, poles constructed of non-
magnetic materials, a robotic device or given component may use suction cups
or similar means to stick to the pole.
Turning to Fig. 4, a perspective view of an embodiment of a joint 1135 of
mounting support assembly 1100 is depicted. Joint 1135 may be a variety of
coupling means including, but not limited thereto, rope, cord, hinge, pivot,
coupling, key, latch, lug, nail, dowel, nut and bolt, screw, latch, lock,
joint and/or a
clamp, etc. Mounting support assembly 1100 may have removable support
plates 1150, such as posts, arms, branches, fingers, frames, legs, rods,
sleeves,
struts, tracks, trusses, shoulders, or studs. The support plates can fix an
angle in
mounting support assemblies 1100 to approximately a predetermined degree
between segment 1110 and 1120, for example. Segment 1120 can be
releasably coupled to another segment 1110 via coupling mechanism 1130
and/or support plate 1150. Coupling mechanism 1130 can be a clamp, rope,
lock, pivot, latch, lug, dowel, nut and bolt, screw, bolt, key, pin, cotter
pin, tie, or
any suitable attachment or binding means. It should be appreciated that
mounting support assembly may be coupled with joints 1135 without the use of
support plates 1150.
Next, turning to Fig. 5, an operative view of an embodiment of the
mounting support assembly in relation to the platform near the base of the
structure is illustrated. Platform 1020 can be lowered to a position at and/or
near
the base of structure 1010. The various components or modules of inspection
system 1000 can be disposed on platform 1020 and/or structure 1010 while the
platform is in a lowered state. As platform 1020 is raised, and/or at
intermittent
stopping points on its path of elevation, the inspecting system captures data
regarding structure 1010. The inspection system can perform the inspection up
CA 02574752 2007-01-22
to the apex of the platform path or any point between the base and the apex
(as
shown in Fig. 6). The platform can be lowered and the inspection components
can be removed or attended to as desired or required.
Turning to Fig. 7, a schematic block diagram of an embodiment of the
communication aspect of inspection system 1000 is illustrated. The data can be
captured by the detector device 1200 (or any other equipment, tool,
instrument,
system, module, mentioned herein), wherein the data can be transferred
between the transmitter and/or receiver 1300 from the detector device 1200 (or
any other equipment, tool, instrument, system, module mentioned herein). The
data can be transmitted by the transmitter and/or receive 1300 to a
controller/processor 1500. The controller/processor 1500 may comprise a mobile
or stationary computing or processing device, television, oscilloscope and/or
various measuring or interactive devices/instruments/equipment, etc. A
technician or user can analyze (or process as deemed appropriate) this data as
it
is received by the controller/processor and/or record the data for future
analysis
or as desired. The technician or user can use a graphical user
interface/computer user interface 1510 (as shown Fig. 8 and Fig. 10) to
send/receive control signals or data from the controller/processor device to
the
transmitter and/or receiver 1300, detector device 1200(or any other equipment,
tool, instrument, system mentioned herein) and/or auxiliary
system/device/instrument 1600. Examples of the controller/processor may be a
variety of processors implemented using hardware, software or a combination
thereof and may be implemented in one or more computer systems or other
processing systems, such as general purpose computer or personal digital
assistants (PDAs).
It should be appreciated that the communication of data and information
transferred among the modules and components of the inspecting system may
be implemented using software and data transferred via communications
interfaces that are in the form of signals, which may be electronic,
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electromagnetic, optical, RF, infrared or other signals capable of being
received
by communications interfaces. The signals may be provided via communications
paths or channels 1350 (or any other communication means or channel
disclosed herein or commercially available) that carries signals and may be
implemented using wire or cable, fiber optics, integrated circuitry, a phone
line, a
cellular phone link, an RF link, an infrared link and other communications
channels/means commercially available.
Other examples of the computer user interface/graphic user interface
1510 may include various devices such as, but not limited thereto, input
devices,
mouse devices, keyboards, monitors, printers or other computers and
processors. The computer/graphic user interface may be local or remote. It
should be appreciated that there may be one or more computer user
interface/graphic user interface 1510 that may be in communication with any of
the components, modules, instruments, devices, systems and equipment
discussed herein. For example, the computer user interface/graphic user
interface 1510 may be remotely located. Such a remote communication of the
computer user interface/graphic user interface 1510 may be accomplished a
number of ways including an uplink/communication path 1350 to a cell telephone
network (e.g., external device/system 1520) or satellite (e.g., external
device/system 1520) to exchange data with a central processing point (e.g.,
external device/system 1520).
The inspection system may also be in communication with an external
device(s) or system(s) 1520 such as at least one of the following
transmitters,
receivers, controllers/processors, computers, satellites, telephone cell
network,
PDA's, workstations, and other devices/systems/instruments/equipment.
Aforementioned external device/systems 1520 may be comprised of one or
plurality and may be locally and/or remotely located.
Further, inspection system 1000 may also comprise or be in
communication with an auxiliary system/device/instrument 1600, as well as a
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plurality of such systems/devices/instruments. Such auxiliary
system/device/instrument 1600 may include, but not limited thereto, the
following:
communication device/system, robot, global positioning system (GPS), laser
devices, positioning device/system, monitoring device/system, laser device or
any other device/system/instrument as desired or required. Aforementioned
auxiliary device/system/instrument 1520 may be comprised of one or plurality
and may be locally and/or remotely located.
Fig. 8 shows an embodiment of a computer/graphic user interface 1510.
User interface 1510 can comprise a graphical user interface as shown. User
interface 1510 can display data received and/or transmitted. The control
signals
sent from or to user interface 1510 can alter the functionality of the
detector, such
as, but not limited to, positioning, monitoring, inspecting, panning, tilting,
zooming, and/or focusing, etc. The control signals sent from or to user
interface
1510 also can alter the functionality of the any component or module of the
inspection system mentioned herein including, for example, the external
device,
auxiliary device, and controller/processor.
Turning to Fig. 9, a schematic plan view of an embodiment of inspection
system 1000 that can be used for inspecting, viewing, positioning and/or
scanning, etc. structure 1010 is shown. Mounting support assembly 1100 is
located at least partially inside of or on the interior position of structure
or
equipment 1010, as schematically illustrated in Fig. 9. Structure 1010 may be
a
variety of structures or equipment such as, but not limited thereto, towers,
piping,
tubing, girders, shafts, elevator shafts, etc. Additionally, inspection system
1000
structure may be adjacent or proximal to the structure or equipment being
inspected, monitored, analyzed or positioned. Any one or all of the
components/modules as illustrated and discussed throughout-detector device
1200, transmitter and/or receiver 1300, power supply 1400,
controller/processor
1500, user interface 1510, external device 1520, and auxiliary
systems/devices/instruments 1600-may be in communication via
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communication path/channel 1350. It should be appreciated that anyone of the
aforementioned components/modules may be singular or plural as well as
separate or integral with other respective components/modules.
Fig. 10(A) shows an embodiment of a computer/graphic user interface
1700. User interface 1710 can comprise a graphical user interface as shown.
User interface 1700 can display data received and/or transmitted. Fig. 10(B)
is
an exploded partial view of the interface shown in Fig. 10(A).
Computer processor(s) 1500, as discussed throughout, may be comprised
of hardware, software or any combination thereof to process the data to
determine the outcome or interesting result of an inspection on a high mast
pole
or given structure or equipment. It should be appreciated that
controller/processor 1500 may be adapted with a variety of software and/or
hardware having a number of anomaly detection (surface and/or subsurface)
algorithms or process capabilities. In an embodiment, the processor may
include
the following algorithm for purpose of inspecting a crack or flaw on a
structure
(e.g., pole): receive the actual width of the base of the structure (e.g.,
pole);
receive the distance between the base of the structure (e.g., pole) to the
crack or
flaw, receive the actual width of the structure (e.g., pole) at the crack or
flaw;
receive the crack points or flaw points (as referenced as 1710, 1720, and
1730)
and width points (as referenced as 1740 and 1750) data according to the
locations illustrated in Fig. 10(B) so as to provide "screen image data"; and
calculate the actual dimensions of the crack or flaw based on the relationship
between the "screen image data" pole width with the actual pole with at the
crack
or flaw. A benefit of this method is that all crack or flaw measurements can
be
performed either in the field or at remote location (e.g., home office or
satellite
location) after the field data have been collected.
In an embodiment, the following method may be implemented:
1. Utilize a measuring device, such as tape, laser, or any type of distance
determining device to measure the actual width of the base of the pole;
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2. Utilize an ultrasonic distance measurement device or manual
measurement (or other automated device) to measure the distance from
the base of the pole to the crack or flaw;
3. Calculate (e.g., via software) the actual width of the pole at the crack or
flaw, which may be accomplished from knowledge of the pole taper or
other information;
4. Calculate (e.g., via software) the screen image dimensions of the crack or
flaw, as shown in Fig. 10(B) as references 1700, 1720 and 1730 (for
example), and entered accordingly, as compared to the screen image
width of the pole, as shown in Fig. 10(B) as references 1740 and 1750 (for
example), and entered accordingly; and
5. Calculate (e.g., via software) the actual dimensions of the crack or flaw
based on the relationship between screen image pole width (e.g., Fig.
10(B))and actual pole width at the crack or flaw.
6. Using only two measured pieces of data, and the manufacturer supplied
pole taper specifications, the software (e.g., prototype LABVIEW -based
software program or other available programming languages) produces
crack or flaw dimensions (height and width).
A benefit of this method, but not limited thereto, is that all crack
measurements
can be performed either in the field or at the home office after field data
have
been collected.
In this application, the terms "computer program medium" and "computer
usable medium" are used to generally refer to media such as removable storage
drive, a hard disk installed in hard disk drive, and signals. These computer
program products are means for providing software to computer system. The
various embodiments include such computer program products. Computer
programs (also called computer control logic) are stored in main memory and/or
secondary memory. Computer programs may also be received via
communications interface and/or communication path/channel. Such computer
CA 02574752 2007-01-22
programs, when executed, enable computer system to perform the features of
the present invention as discussed herein. In particular, the computer
programs,
when executed, enable processor to perform the functions of various
embodiments of the present invention. Accordingly, such computer programs
may represent controllers of a computer system. In an embodiment where the
invention is implemented using software, the software may be stored in a
computer program product and loaded into computer system using removable
storage drive, hard drive or communications interface. The control logic
(software), when executed by the processor, causes the processor to perform
the
functions of the invention as described herein. In another embodiment, the
invention is implemented primarily in hardware using, for example, hardware
components such as application specific integrated circuits (ASICs).
Implementation of the hardware state machine to perform the functions
described
herein will be apparent to persons skilled in the relevant art(s). In yet
another
embodiment, the invention is implemented using a combination of both hardware
and software. The methods described above could be implemented in a variety
of available program languages.
The following disclosure is of a commercially available embodiment of the
disclosed high mast inspection system.
Camera Pod Assembly
Referring now to Fig. 11, a camera pod assembly, 8, includes a power
supply, camera pod, mounting bracket assembly, and wireless communication
transceiver. The camera pod assembly is adapted to be affixed to luminaire
ring
1020 of a high mast light tower with the mounting bracket assembly. Referring
to
Fig. 11, essentially, camera pod assembly 8 includes a camera pod, 10, which
includes a still/video camera remotely controlled (pan, tilt, zoom, and focus)
and
which is powered by a power source, 12 not seen in Fig. 11), which suitably is
a
rechargeable battery. Camera pod 10 is removably affixed to a bracket
assembly, 14, which can be quickly connected/disconnected to luminaire ring
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1020 with a bracket, 16, which conveniently operates with a "thumb screw", 17,
hand operable to quickly connect and disconnect camera pod assembly 8 to
luminaire ring 1020 or any other component of a light ring assembly. A variety
of
other quick connect/disconnect designs can be envisioned and it matters only
that a service technician can readily operate the connect/disconnect assembly
quickly and that it reliably stay connected. Finally, camera pod assembly 8
carries a wireless communications transceiver and antenna (not seen in the
drawings but self-contained within camera pod 10) for transmitting the camera-
captured images (or other detector outputs) to a near or remote
receiver/transceiver and for receiving signals for operating (e.g., pan, tilt,
zoom,
and focusing) the camera. The particular camera pod illustrated has such
wireless communications transmitter built into it; although, a separate such
unit
can be provided. A direct-wired configuration could be used for this and for
other
related applications.
While a battery associated with each camera pod currently is
contemplated, the operator can connect a single battery or power source
carried,
for example, by one of the camera pods to the other camera pods for power.
Alternatively, other power sources, such as, for example, solar collectors,
fuel
cells, or the like, may find utility for powering the camera pods and such
other
power sources are within the scope of the present invention.
Typically, between 3 and 4 camera pod assemblies are used for any given
mast being inspected to ensure a complete 360-degree view of the structure.
The number of cameras is an input variable to the recorder software (see
below).
As illustrated in Fig. 11, an Internet Protocol (IP) based camera is provided
with
its own power source and an IEEE 802.11 wireless transceiver. Camera control
and images are sent digitally through the wireless network. Low-level wireless
protocols are auto-configuring. Wireless PC card transceivers with small '/
wave
diverse antennas are used in the camera pods.
17
CA 02574752 2007-01-22
Most high mast lamping systems lend themselves to either three or four
camera pod assemblies, depending upon the number of luminaires (lamps).
Regardless, it is desirable to view all 360 circumference of the pole so that
the
entire exterior surface can be inspected and recorded. In a 3-camera system,
each camera has the potential to view its own 120 sector of the pole with
some
overlap with the adjacent cameras. In a 4-camera system, each camera has the
potential to view its own 90 sector of the pole with significant overlap,
which is
slightly better in that a flatter image is viewed with less distortion.
Cameras also
may be zoomed in so as to have as little image overlap as possible and to
yield
images with better definition of the pole surface.
High Mast Viewer/Transceiver
Fig. 12 shows the MastCheckT"" viewer screen. Images recorded using
the MastCheckT"" recorder (See Figure 14) are presented. From one to four
images may be shown. The images may be played back, stopped, and manually
viewed frame by frame. Frame numbers are recorded with the image and are
displayed for reference purposes. Images may be enlarged, edited, entitled,
and/or saved as individual or sets of images.
Global Positioning System (GPS) information, showing the pole location,
taken at the time of recording is shown in the lower left. The recording
operator's
comments are included in the bottom center and the crack analysis section on
the lower right.
The host recorder workstation (laptop computer) uses a battery powered
wireless access point (AP) for all communications with the cameras. These form
a network that uses a fixed architecture with IP addresses. Low-level wireless
protocols are auto-configuring. The workstation AP also has a high gain panel
type diversity antenna to insure a quality signal, and high data throughput.
This
is placed near the base of the pole or on the maintenance vehicle aimed upward
at the cameras.
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CA 02574752 2007-01-22
Crack Analysis Help Screen
The current commercial version utilizes the crack analysis regimen, as
described above in connection with Figs. 10A and 10B, and the description
thereof.
High Mast Recorder/Transceiver
Fig. 13 shows the MastCheckT"~ recorder screen. Images are recorded
from one up to four wireless camera pods (across the top). All of the images
are
recorded independently or at the same time. The recorder also may be paused
during the recording. Frame numbers are recorded with the image and are
displayed for reference purposes.
Global Positioning System (GPS) information, showing the pole location,
is recorded at the start of recording and is shown in the lower left. Pole
information is entered and recorded for use in later analysis. The recording
operator may also make general comments about the recording. Record control
is in the lower right of the screen. A standard MS WINDOWS or similar
directory
holds all of the recorded data. Comments and pole info are saved at the end of
the recording.
Communication Block Diagram for the Inspection System
The block diagram of Fig. 7 was simplified for a commercial version of the
disclosed high mast inspection system, as shown in Fig. 14. A
controller/processor, 40, drives a computer interface/graphic user interface
or
display, 42, enabling the operator to visualize the data generated by the
detector
device. Controller/process 40 can be located remote from the mast poles being
surveyed, though it can be carried along with the operator in the field.
Auxiliary
device(s) (GPS, for example), 43, can be inputted directly into
controller/processor 40, if desired.
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CA 02574752 2007-01-22
A transceiver/router, 44, optionally can be used to transmit data to
controller/processor 40 and to receive instructions from controller/processor
40.
A transceiver, 46, detector, 48, and auxiliary device(s) 43, often are a
single unit,
such as camera pod assembly 8; although, separate units can be used. Any or
all of the communication between any or all of the devices in Fig. 15 can be
via
hard wire and/or wireless communication.
Functional Flow Diagram for the Inspection Operation
The functional flow diagram for the operation of the inventive inspection
system is set forth in Fig. 15. Functional inputs include, inter alia, user
inputs,
block 51; camera input, block 52; GPS input, block 53; and the pole scan,
block
54. The functional inputs become acquired data, block 55, which are stored,
block 56. The stored data in block 56 can be outputted to a computer or
similar
display/analysis device for becoming inspection data, block 57.
The inspection data in block 57 also can be inputted along with stored
data from block 57 for playback and analysis, block 58, to determine whether
an
anomaly has been detected, decision block 59. If no anomaly is detected, an
inspection report is completed, block 66, which is recorded in a database,
block
67, and the inspection is completed (ended). If, however, an anomaly is
detected, a determination as to whether the anomaly is of concern is made at
decision block 60. If the decision is made that the anomaly is not of concern,
the
anomaly is recorded, block 61, and the inspection report is made, as described
before.
If the anomaly is of concern, a determination as to whether to put the
anomaly on watch status, decision block 62, is made. If no immediate watch is
required, the anomaly is cataloged for note at a future inspection, block 63,
and
the inspection report is made, as before. If the watch decision is positive,
then
an action watch is created, block 64, and a next inspection of the anomaly is
made, block 65, and this action/decision is recorded on the inspection report.
CA 02574752 2007-01-22
The foregoing functional flow diagram establishes a baseline for existing
poles and crack data and other characteristics such as, for example, corrosion
collected for other poles, an opportunity exists for monitoring the progress
of
cracks and other characteristics and employing predictive algorithms for pole
maintenance and/or replacement. While such analytical tools have not yet been
developed, the inventive inspection system now will enable the skilled artisan
to
develop and apply these and other analytical tools to high mast poles.
While the invention has been described with reference to various
embodiments, those skilled in the art will understand that various changes may
1o be made and equivalents may be substituted for elements thereof without
departing from the scope and essence of the invention. In addition, many
modifications may be made to adapt a particular situation or material to the
teachings of the invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the particular
embodiments disclosed, but that the invention will include all embodiments
falling
within the scope of the appended claims. All citations referred herein are
expressly incorporated herein by reference.
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