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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Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
Slag pots used in blast furnace operations are prone to crack formation due to extreme temperatures, thermal cycling, and mechanical stresses. Current manual inspection methods are subjective and may miss critical defects. The challenge is to develop an automated, non-contact solution to accurately detect, classify, and report cracks on slag pots in a high-temperature steel plant environment, enabling safer and more reliable operations.
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Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
Torpedo ladles used for hot metal transportation are currently secured using manually placed wooden scotch blocks, exposing operators to significant safety risks from moving equipment, high temperatures, and pinch points. The plant operates 51 torpedo ladles of varying sizes, with scotching requirements differing based on wheel position and track gradient.The challenge is to develop an automated, remotely operated scotching system integrated onto the torpedo ladle itself, capable of deploying and retracting scotch blocks without manual intervention. The solution must be self-powered, operate reliably in harsh steel plant conditions (up to ~250°C), withstand heat, dust, and sparks, be fail-safe during emergencies, and either use existing wooden scotch blocks or a suitable alternative material with equal or better performance. Modifications to existing equipment or infrastructure may be considered.
Automation of Hot Metal Sampling in Blast Furnace Runner
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
Hot metal samples are manually collected from blast furnace runners three times per cast, exposing operators to molten metal, extreme heat, fumes, glare, and splash hazards. We seek autonomous or remote-operated solutions that can safely and reliably collect representative samples with equal or better consistency while operating in harsh runner conditions and eliminating human exposure.
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Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
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Rewards proportional to the value add! Few solutions could be available! Efforts might be needed to customize the solution.
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Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
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