Alstom Inspection Robotics

Company
Technology
Products
2009-10-30

INSPECTION ROBOTICS Ltd

Introduction of my self

Ekkehard Zwicker:
In 1994, Ekkehard Zwicker received an M.Sc. with honors in mechanical
engineering from the Technical University of Karlsruhe, and in 1998 gained a
Ph.D. with honors from the Swiss Federal Institute of Technology (ETH) in
Zurich.
From 1998, he continued as a senior researcher at the Centre for Product
Development at the ETH.
In parallel, he founded and built up an ETH spinoff company focusing on digital
product design.
In 2008, he joined Alstom Inspection Robotics, where he focuses on defining and
executing the strategy of the company.

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 Importance of parent organisation
issues occurred affecting the relationship
Mother with the parent organisation?
Organization

Key aspects
related to the founding team
that make the success of
a venture
Success Factors
Founding of Technology Spin off Firm
Team Spin offs?

Changes of
business model/ technology/
since foundation?
(adaptability)
Environment

What components of the start-up

“ecosystem” could be improved?
Content

Alstom Inspection Robotics — Basic Idea and Concept

Swiss Federal of Technology — ASL

Alstom / Alstom Power Service — Overview and Motivation

Alstom Inspection Robotics — Overview

Alstom Inspection Robotics — Products and Technology

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purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Content

Alstom Inspection Robotics — Basic Idea and Concept

Swiss Federal of Technology — ASL

Alstom / Alstom Power Service — Overview and Motivation

Alstom Inspection Robotics — Overview

Alstom Inspection Robotics — Products and Technology

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© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject
to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 Importance of parent organisation
issues occurred affecting the relationship
Mother with the parent organisation?
Organization

Key aspects
related to the founding team
that make the success of
a venture
Success Factors
Founding of Technology Spin off Firm
Team Spin offs?

Changes of
business model/ technology/
since foundation?
(adaptability)
Environment

What components of the start-up

“ecosystem” could be improved?
Alstom Inspection Robotics – The Idea and Set Up

Power Generation Transport Oil & Gas (Up-/Mid-/Down-Stream)

Inspection
Robotics

Mobile Inspection
Robotics Technology
- Pape 7
Alstom Inspection
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All rights reserved. - Company
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 Alstom Inspection Robotics – The Idea and Set Up

Power Generation Transport Oil & Gas (Up-/Mid-/Down-Stream)

Inspection
Robotics  Independent
Legal Entity (AG)
 Shareholder
Alstom
 continuous grow up ETH / ETH Prof.
to 50 head counts in Management
the next 3-5 y  Board
 high pace in R&D A. Schläpfer (President)
and industrialization S. Hess
G. Albiez
 experts on rugged R. Siegwart (ETH)
A. Traxler (external)
mechatronics
 Management
E. Zwicker (CEO)

Mobile Inspection W. Zesch (CTO)

Robotics Technology
- Pape 8
Alstom Inspection
© ALSTOM 2008. Robotics
All rights reserved. - Company
Information / Products
contained in this / Technology
document is provided - information
without liability for 2009/05/17 purposes only and is subject
to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 Importance of parent organisation
issues occurred affecting the relationship
Mother with the parent organisation?
Organization

Key aspects
related to the founding team
that make the success of
a venture
Success Factors
Founding of Technology Spin off Firm
Team Spin offs?

Changes of
business model/ technology/
since foundation?
(adaptability)
Environment

What components of the start-up

“ecosystem” could be improved?
Content

Alstom Inspection Robotics — Basic Idea and Concept

Swiss Federal of Technology — ASL

Alstom / Alstom Power Service — Overview and Motivation

Alstom Inspection Robotics — Overview

Alstom Inspection Robotics — Products and Technology

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to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 Impulse-Presentation
ABB Robotics, 5.12.2008

Machines that know what they do

Autonomous Systems Lab

Prof. Roland Siegwart
ETH Zurich

Autonomous Systems Lab Zürich

Autonomous Systems Lab

 Mission
◦ Create machines
that know what they do
 Research Lines
 Design of robotic and mechatronic systems
 Inspection-, Walking- and Micro-Robots, Space Rovers
 UAV – Solar Airplane, Micro-Helicopters

 Navigation and mapping

 Mapping and Reasoning in real world settings
 Navigation and Planning in dynamic environments

 Product design methodologies and innovation

Alstom Inspection Robotics - Company / Products / Technology - 2009/05/17

Zürich
Content

Alstom Inspection Robotics — Basic Idea and Concept

Swiss Federal of Technology — ASL

Alstom / Alstom Power Service — Overview and Motivation

Alstom Inspection Robotics — Overview

Alstom Inspection Robotics — Products and Technology

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to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 Alstom One in four of the world’s light
bulbs is powered by Alstom technology

Very high speed

Key Figures: Tram / Metro Interurban / Regional High Speed

Sales : €35.5 billion

Employees: around 76,000
Global presence: 70 countries
Turnkey Systems

Power Transport
N° 1... in turnkey power plants
N° 1... in hydro turbines and generators
N° 1... in very high-speed trains,
N° 1... in service for utility power generation high speed trains
N° 1... in air quality control systems and tilting trains
N° 2... in urban light rail and
Full Plant Service tram systems, commuter and regional
GT/ST Turbines Generator trains, services, signaling and systems

Systems
Boiler / Construction Environmental Nuclear (Conventional Part) Coal Wind Gas Hydro

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purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Alstom Power: 50,000 employees in 70 countries

 26 Manufacturing units
 53 Engineering centres
 38 R&D centres
 200 Local service centres
 25 Technical expertise centres

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purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
“Alstom Information to Investors”

Inspection Robotics
is strategic for Alstom

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Context of Alstom Inspection Robotics
The Alstom Venturing Network

Universities / Research Alstom Venturing Companies

Mobile Robotics

Water Jet
Cleaning & Cutting

NDT Sensor
Technology

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© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject
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purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 Importance of parent organisation
issues occurred affecting the relationship
Mother with the parent organisation?
Organization

Key aspects
related to the founding team
that make the success of
a venture
Success Factors
Founding of Technology Spin off Firm
Team Spin offs?

Changes of
business model/ technology/
since foundation?
(adaptability)
Environment

What components of the start-up

“ecosystem” could be improved?
Inspection Robotics for Power Plant Inspection
Inspection in
Power Plants means
− detection of
• cracks
• corrosion / erosion
• leaks
• flaws
− cleaning / preparation
− machining
of critical components
− Piping
− Boiler (boiler tubes, water
wall, welding, …)
− Pressure Vessels
− Steam Turbine (steam
chest, rotor, blades, …)
− Gas Turbines (Rotor,
Blades, …)
− Generator (Rotor, Stator,
water box, …)

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Refinery Service Business: Drivers and Technology

Business Goal Prerequisite Enabling Technology (Need)

Life Time Assessment Inspection Technology

 - NDT (UT, PA UT, EC, EMAT, ….)
Life Time Extension - Vision
Condition & - Cleaning
Risk Assessment - Machining

Outage Planning
 Data Acquisition / Data Management
Outage Optimization - Measurement / Data Acquisition
- Positioning / Navigation
Productivity

Outage Execution Trending

 - Data Analysis / Data Interpretation
Outage Reduction
On Site / In Situ Automation / Mobile Robotics
Operation - Compact, Agile
- High Temperature
Forced Outage - Protection (hazard environment)
Management - Wireless / Autonomous Navigation

Possibilities and Opportunities of Mobile Robotics in Refinery Inspection - Pape 20

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to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 Importance of parent organisation
issues occurred affecting the relationship
Mother with the parent organisation?
Organization

Key aspects
related to the founding team
that make the success of
a venture
Success Factors
Founding of Technology Spin off Firm
Team Spin offs?

Changes of
business model/ technology/
since foundation?
(adaptability)
Environment

What components of the start-up

“ecosystem” could be improved?
Content

Alstom Inspection Robotics — Basic Idea and Concept

Swiss Federal of Technology — ASL

Alstom / Alstom Power Service — Overview and Motivation

Alstom Inspection Robotics — Overview

Alstom Inspection Robotics — Products and Technology

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to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
“History”

2006 2007 2008 2009 2010

March. – Sept. 2006
- ETH-Alstom Feasibility Study
Mobile Inspection Robotics

Oct. 2006 – Sept. 2009

- CTI Project Mobile inspection robotics
Dec. 2009
Nov. 2006 - Relocation within
Foundation of AIR Technopark

Jan. 2007:
- Start of operation
- Location: Technopark (ETH)
2007: 2008: 2009 / 2010
- Know How Build Up - Strategy Development - Strategy Execution
- Industrialization of - Modular Robotic Module - Modular Robotic Module
Alstom Developments Development Development
- 3 Employees - 8 Employees - Non Alstom Customer
- 2009: 14 Employees
- 2010: 16 Employees
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purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Alstom Inspection Robotics:
Drivers and Technology – Core Competences
Business Need Product Requirement AIR Core Competences

Mobility Robust Mechanical Design

access to human  Free Movement  Drives / Steering
inaccessible areas  Obstacle Handling  Miniaturization
 Compactness / Agility  Manufacturing
 Protection (immersion etc.)

Autonomy / Automation High Tech Mechatronic /

 Positioning / Navigation Electronic Design
 Adaptive Movement  On board computing

Modularization
 Offline / Online Teaching (controller, programming)
 navigation (sensor + logic)
Efficiency / Reliability  Integration navigation – data
acquisition
System Integration
 Integration of Navigation and Application Integration
Data Acquisition / Data  Integration of Data Acquisition
Management / / Data Management -
Data Analysis Positioning / Navigation
 System integration
Robustness - watch
Data Acquisition /  Temperature - clean
Data Management /  Immersion - measure
Data Analysis (HydroCarbons, Water etc.) - grab / repair

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 Innovation in Robotics

full autonomy Robotics

degree of autonomy

full

Scanner
automation

manual

Manual
guided free movement free movement
movement on regular surfaces on complex surfaces /
no obstacle handling obstacle handling
Possibilities and Opportunities of Mobile Robotics in Refinery Inspection degree of25 mobility
- Pape
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Innovation in Robotics
Highly compact versatile inspection robot
Navigation Mobility
 3D camera  free movement on complex
- navigation support shaped surfaces
- position estimation  right a away turn
- measure  obstacle handling 1760 mm
- object recognition  climbing over steps / edges
 Autonomy: line following
- following a drawn line
- following an edge
- following a weld seem

10 cm
Possibilities and Opportunities of Mobile Robotics in Refinery Inspection

- Pape 26
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Innovation in Inspection Technology

Application System Purpose / Characteristics / details

Watch Camera Navigation
 Micro pan- / tilt Visual Inspection
camera
3D Camera Navigation / Visual Inspection

integrated application
 3D navigation support
 position estimation
 measure scene (e.g. accurate distances [mm])
 object recognition
Detect EC  Material (ferrite, austenitic) distinction
 Weld following

Measure NDT UT Classic, Phased Array, TOFD

EMAT Guided Waves, Wall thickness measurement
EC Surface Crack
Dimensional High-accuracy Laser Displacement Sensor
Clean WaterJet Cleaning Cleaning of surfaces
Cut WaterJet Cutting Cutting
Possibilities and Opportunities of Mobile Robotics in Refinery Inspection - Pape 27
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Platform Concept

Application: Integration of Robotics System & Application System (Inspection)

Robotic System (Positioning, Navigation, …) Application System (NDT, Cleaning, …)

- Boiler Crawler
- Pipe Crawler
AIR Alstom 3rd Party
(Inspection Tech.)

Robotic Module-/ Technology Platform Application

- Buggy Family Componet- / Module- / Technology Platform
- Track Drive Family (Diris Drive)
- Control Unit
-...
AIR Alstom Net 3rd Party
Basic Robotic Components - Sensors - Sensors
- Magnetic Wheel (Family) - Water Jet Tech. - Detectors
- Motor (Family) -... -...
-...

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Business Model: Customer Value Chain

 Value Statement  Tailored Application  Inspection  Assessment

 Requirements Operation  Trending
 System Concept  Inspection Data
Management

Inspection Robotics Application Configuration Robotic Inspection Data

Assessment / Engineering Operation Processing

Inspection Assessment Application Engineering

fixed price /
daily rate Application Operation
fixed price /
daily rate
Customer /
- Evaluation of Inspection Robotics - Configuration of - System rental 3rd Party
Potentials robotic system - System operation
- Inspection Robotics Requirements - Application integration - Data acquisition / management
- Inspection Robotics Concept
Fixed Price (Prerequisite: Inspection Assesment)
- Value Definition / KPI Definition
fixed price / fixed price /
Application Development daily rate Application Rental daily rate
- Robotic Module Engineering - Training, Start Up and Handover
- Application Module Engineering - System Rental
- System Integration fixed price /
(Robotic / Application System) Application Support daily rate
- On Site Repair / Maintenance
- Operation support
(onsite / remote)
Fixed Price
daily rate
Field operation support
- Coaching
- Operation
- Training
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Content

Alstom Inspection Robotics — Basic Idea and Concept

Swiss Federal of Technology — ASL

Alstom / Alstom Power Service — Overview and Motivation

Alstom Inspection Robotics — Overview

Alstom Inspection Robotics — Products and Technology

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to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
MRS Series
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 Watch Detect Measure Clean

MRS 100 Series

Versatile Inspection Robot

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MRS 100 Series: Configuration Examples

— Application
 inspection of cylindrical
components different diameters
— Technical Key Features
 modular & flexible design
 scan length 80 to 500mm
 flexible wheel distance
 handy and robust

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MRS 100 Series: Disc Scanner

Versatile Automated Rotor Inspection System

Scalable:
4h / disc
Massive time gain by using
multiple scanners in parallel

Reliable:
Human error is engineered out

Manual Method Versatile:

Very short set-up time for the
30min / disc inspection of a new rotor disc
geometry.

Modular:
Can be easily adapted for any
kind of automated rotor inspection
Automated Method
Not limited to ST discs

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Alstom Inspection Robotics - Company / Products / Technology - 2009/05/17 - Pape 36
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to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
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MRS 100 Series: Rotor Scanner

Inspection of cylindrical rotor parts

Data display and storage Motor control

Vario rotor module

Phased Array system

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Rotor Shaft Inspection

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 Watch Detect Measure Clean

MRS 200 Series

Versatile Inspection Robot (Watch, Detect, Measure)

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MRS 200 Series
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MRS 200 Series:
autonomous navigation support for automated weld inspection
Navigation
 3D camera
- navigation support
- position estimation
- measure scene (e.g.
accurate distances [mm]) weld detection
- Object recognition
 line following
- following a drawn line
- following an edge

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3D Camera: System Overview

Stereo Camera Wireless connection to remote PC

Dimmable LED Light sources (directed and diffuse)

Pan/tilt mount for stereo
camera

Embedded PC with Intel Atom

1.1 GHz and 1GB RAM running Battery pack for 40min
XPe driving

- Pape 42
42
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 Watch Detect Measure

MRS 400 Series

Versatile Inspection Robot

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purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
MRS 400 Series
Highly compact versatile inspection robot

1760 mm

Capabilities / Features
- free movement on complex
shaped surfaces
- right a away turn
- obstacle handling
- climbing over steps / edges
10 cm

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purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 Clean Measure

MRS 500 Series

Water Jet Cleaning and Inspection

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Boiler: Waterwall Cleaning and Inspection

Avoid internal scaffolding of boiler furnaces and improve the cleaning and inspection quality
Using a “façade-cleaning” robot concept, combined with waterjet cleaning and ultrasonic testing on the same vehicle, a
time reduction of 90% can be achieved (about 10 days of availability)

Lab tests

50m
Cold side results
Boiler crawler: 7kg payload

35m
35m

Old method: 2 days of scaffolding Hot side results

2 days of cleaning
4 days of inspection
10 days of labour
2 days of un-scaffolding

Alstom Inspection Robotics - Company / Products / Technology - 2009/05/17 - Pape 46

© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject
to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Basis: Special Developed Water Jet Technology

Alstom Inspection Robotics - Company / Products / Technology - 2009/05/17 - Pape 47

© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject
to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 Watch Measure

AES 200 Series

UT / EC Bore Hole Inspection

Alstom Inspection Robotics - Company / Products / Technology - 2009/05/17 - Pape 48

© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject
to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 AHS 200 Series:
Generator and Turbine Bore Scanner
Highly compact on-site non-destructive assessment (ultrasonic, eddy current,
video) of bores with / without tapers

Rotor

Counter-bore shoulder

System with ultrasonic module System in deployment housing

Alstom Inspection Robotics - Company / Products / Technology - 2009/05/17

- Pape 49
© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject
to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
 Measure

HES 100 Series

UT Inspection of Butt Welds

Alstom Inspection Robotics - Company / Products / Technology - 2009/05/17 - Pape 50

© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject
to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
HES 100 Series
efficient and reliable phased array UT Inspection of Butt Welds
— 12mm height, allows scanning of 1.5’’ – 2’’ tubes
— Phased Array ultrasonic technology with encoder feedback
— Replaces radiography under ASME code case 2235/6 (UT
in lieu of RT): Faster and more precise assessment
— Can be adapted to all geometries up to 10’’ tubes

System
Alstom Inspection Robotics - Company / Products / Technology - 2009/05/17 - Pape 51
© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject
to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Contact

ALSTOM Inspection Robotics Ltd

Technoparkstrasse 1
8005 Zurich, Switzerland
Phone +41 (0) 44 633 75 96
Fax +41 (0)44 633 14 82
info@inspection-robotics.com
www.inspection-robotics.com

Alstom Inspection Robotics - Company / Products / Technology - 2009/05/17 - Pape 52

© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject
to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular
purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
www.inspection-robotics.com

INSPECTION ROBOTICS Ltd