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Detection of weld cracks in structural members

We are looking for an automated inspection solution to detect loose fasteners and cracks in welds in structural members.

  attractive

 
Reward money is paid in exchange of legally acquiring the solution, implementing it to solve the problem and meeting the success criteria. Milestones for paying the reward money would depend upon the complexity of challenge and maturity of the proposed solution, which would be discussed with the solver as soon as the proposed solution is selected by us.

  15 Apr 2025

 

Challenge details:

The buildings in any manufacturing plant comprise of many load bearing structures (e.g. Truss supporting the roof, beams, pillars erected from the base, etc.). These load bearing structures support crane movement, ducts, cable trays, overhead pipelines, etc. and are subjected to static and/or dynamic (cyclic) loading. The structural members of these trusses are joined by fasteners (nuts & bolts) and/or welding. There are chances of loosening of fasters and/or cracks initiated in weld joints, thus creating a potential safety hazard condition. 

Manual inspection of all such joints (nut & bolts and weld joints) to detect loosening of fasteners and cracks in weld joints is not possible as there are large number of trusses in the plant. 

We are thus seeking a solution that can facilitate quick inspection of these structures and generate alerts if any loose fasteners or cracks observed in the joints. The inspection solution should be such that it can be used by a person standing on the ground & he/she should be able to check the nut bolt and weld joint condition.

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Detection of coolant carryover from mill
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Taphole drill alignment for hot metal tapping in blast furnaces
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Mandrel plain bearing failure prevention
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
Plain bearing conditions are monitored manually or with basic tools, which often fail to detect early signs of wear, resulting in unexpected failures and costly repairs. At the start and end of rotation, when the shaft speed is low, boundary lubrication occurs, causing intermittent contact between the Roll Shaft and the plain bearing, leading to wear over time. A solution is needed for real-time, accurate, non-intrusive condition monitoring that can withstand high temperatures (45-80°C) and harsh environments.
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Visual inspection inside bustle main of blast furnaces
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
We are seeking high-temperature visual inspection solutions to detect refractory damage, cracks and material build-up inside blast furnace blowstock and bustle main during shutdowns at temperatures of ~800-1000°C.
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Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
We are seeking the solution which should operate reliably under continuous production conditions and enable timely intervention before coolant carryover impacts product quality downstream. The solution should be scalable across multiple rolling mill lines.
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Automated Vehicle Parameter Verification on Running Assembly Line (VPN).
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
We are seeking solution for automated, non-contact measurement of all critical vehicle dimensional parameters while the vehicle is moving on the assembly line conveyor before dispatch to ensure compliance with Vehicle pass off norms (VPN).
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Taphole drill alignment for hot metal tapping in blast furnaces
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
Taphole drill alignment is currently verified manually near the blast furnace front, exposing operators to high temperatures and relying heavily on operator judgement. We seek an automated solution to identify the taphole centre, verify drill tool orientation and seating, and provide real-time alignment feedback, improving safety, drilling consistency, and operational reliability.
...
Mandrel plain bearing failure prevention
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
Plain bearing conditions are monitored manually or with basic tools, which often fail to detect early signs of wear, resulting in unexpected failures and costly repairs. At the start and end of rotation, when the shaft speed is low, boundary lubrication occurs, causing intermittent contact between the Roll Shaft and the plain bearing, leading to wear over time. A solution is needed for real-time, accurate, non-intrusive condition monitoring that can withstand high temperatures (45-80°C) and harsh environments.
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