Problem Description

Non-Destructive Testing (NDT) is a critical component of preventive asset maintenance for large-scale industrial infrastructure such as transmission towers, pipelines, storage tanks, and industrial facilities. Despite its importance, current NDT practices remain constrained by high inspection costs, operational downtime, limited access to complex geometries, and significant safety risks for human inspectors. Many inspection tasks require scaffolding, rope access, or shutdown of critical systems to facilitate operator task, making frequent inspection costly and disruptive.

To address these challenges, this project proposes Flying Hand, an aerial robotic manipulation system designed to perform contact-based non-destructive testing on hard-to-reach industrial assets. By combining a multirotor aerial platform with a robotic manipulator arm and a contact-based NDT end-effector, Flying Hand enables targeted inspection without interrupting ongoing operations or exposing personnel to hazardous environments.

Flying Hand is designed as an operator-deployed yet autonomously executing inspection system. A trained operator manually pilots the drone to a designated Area of Interest (AOI) using a ground control station. Upon arrival, the operator identifies the specific Point of Interest (POI) directly from the real-time video feedback at the ground control station. From this point onward, the system autonomously plans and executes precise arm motions to position the end-effector onto the selected POI, maintains stable contact during data acquisition, and relays inspection data back to the ground station.

The primary objective of this project is to design and implement an aerial robotic inspection system capable of performing multiple high-precision contact-based NDT measurements within a single flight while maintaining stability under realistic environmental disturbances such as wind, reducing inspection time, cost, and risk while laying the foundation for future fully autonomous aerial inspection systems.

Use Cases

Use Case 1: Industrial Asset Inspection for Predictive Maintenance

The maintenance team can perform routine inspections of critical industrial assets without disrupting regular operations. Using the ground station, an operator deploys the Flying Hand, which autonomously navigates around structures and maps key inspection areas. It streams relevant observations in real time, allowing the operator to briefly take control and examine specific spots if needed. This capability helps the team identify potential issues early and plan maintenance proactively, reducing the risk of unexpected failures. The Flying Hand returns automatically upon completion of the inspection cycle.

Use Case 2: Real-Time Powerline Tower Monitoring and Maintenance Planning

Utility maintenance teams can assess transmission towers without interrupting power delivery. Using the Flying Hand, operators reach areas that are difficult or unsafe to inspect manually. The drone navigates around the structure, surveying regions where protective coatings are most vulnerable to weather and corrosion. It streams observations in real time, allowing operators to examine specific spots if needed. This enables early detection of coating degradation and proactive maintenance planning. The Flying Hand returns automatically once the inspection is complete.