Robotic pipe inspection with ultrasonic sensor arrays

The aim is to develop an ultrasonic sensor system and associated data analysis tools to extract information from the interior of a buried pipe, such as a water or gas pipe.

The first major challenge is to extract accurate and relevant information, which in this case will relate to the current condition (or "health") of the pipe. For example, this could mean the local pipe geometry or the presence of corrosion and cracking. This requires the development of novel ultrasonic non-destructive systems that can accurately detect, locate and size defects and other relevant conditions in a variety of pressurised and partially filled pipes with a flow.

The second challenge is to extract this information reliably, which involves developing statistical methods for minimising the effects of uncertainty in the measurements (e.g. position). One important approach to be explored here is to use the ultrasonic data as a signature to locate the sensors - this is usually termed data-driven imaging.

The third major challenge is in the development of the sensing and data analysis hardware which needs to be energy efficient and integrated with the other systems on-board the robots. This will mostly be hardware available within the Bristol group but work will be required to develop it into a working sensors system.

The ultrasonics and non-destructive testing (UNDT) group in Bristol are uniquely placed to address these issues, with complimentary experience of imaging and ultrasonic system design and integration that will result in an output much greater than the sum of its parts.

The project will combine experimentation, with simulations, which together will lead to a deep understanding of the performance of the new sensors. Parts of the project will also require data analysis and signal processing. In this way the project requires good all-round engineering skills.

By the end of the project it is expected that a demonstrator device will be made and tested on an industrial relevant scenario, e.g. a real buried pipe in a test facility. The project will also link up with various industrial partners, such as water supply companies in order to develop sensors systems suitable to the real-world applications.

The proposed CDT in NDE will deliver impact (Industrial, Individual and Societal) by progressing research, delivering commercial benefit and training highly employable doctoral-level recruits able to work across industry sectors.

Industry will benefit from this CDT resulting in competitive advantage to the industrial partners where our graduates will be placed and ultimately employed. The global NDE market itself has a value of USD15 billion p.a. [Markets and Markets NDE report January 2017] and is growing at 8% per year. Our partners include 49 companies, such as Airbus, Rolls-Royce, EDF, BAE Systems, SKF and Shell, whose ability to compete relies on NDE research. They will benefit through a doctoral-level workforce that can drive forward industrial challenges such as increased efficiency, safer operation, fewer interruptions to production, reduced wastage, and the ability to support new engineering developments. Our 35 supply chain partners who, for example, manufacture instrumentation or provide testing services and are keen to support the proposed CDT will benefit through graduates with skills that enable them to develop innovative new sensing and imaging techniques and instrumentation. To achieve this impact, all CDT research projects will be co-created with industry with an impact plan built-in to the project. Our EngD students will spend a significant amount of their time working in industry and our PhDs will be encouraged to take up shorter secondments. This exposure of our students to industry will lead to more rapid understanding, for both parties, of the barriers involved in making impact so that plans can be formulated to overcome these.

Individual impact will be significant for the cohorts of students. They will be trained in an extremely relevant knowledge-based field which has a significant demand for new highly skilled doctoral employees. These graduates will rejuvenate an ageing workforce as well as filling the doctoral skills and capability gaps identified by industry during the creation of this CDT. Our industrial partners will be involved in training delivery, e.g. entrepreneurial training to equip our graduates with the skills needed to translate new research into marketed products. Many of the partners are existing collaborators, who have been engaged regularly through the UK Research Centre in NDE (RCNDE), an industry-university collaboration. This has enabled the development of a 5,10 & 20 year vision for research needs across a range of market sectors and the CDT training will focus on these new priorities. Over the duration of the CDT we will actively discuss these priorities with our industry partners to ensure that they are still relevant. This impact will be achieved by a combination co-creation and collaboration on research projects, substantive industrial placements and as well as communication and engagement activities between academic partners and industry. Events aimed at fostering collaboration include an Annual CDT conference, technology transfer workshops, networking events as well as university visits by industrialists and vice versa, forming a close bond between research training and industrial impact. This approach will create lasting impact and ensure that the benefits to students, industry and society are maximised.

Society will benefit from this CDT through the research performed by our CDT graduates that will underpin safety and reliability across a wide range of industries, e.g. aerospace, energy, nuclear, automotive, defence and renewables. As NDE is an underpinning technology it feeds into many of the UK Government's Industrial Strategy Challenge Fund Grand Challenges, for example in energy, robotics, manufacturing and space. It is aligned to the EPSRC prosperity outcomes, e.g. the Productive Nation outcome requires NDE during manufacture to ensure quality and the Resilient Nation requires NDE to ensure reliable infrastructure and energy supplies.